Hinged slab system of building

ABSTRACT

A modular system of building constructed by casting reinforced slabs having embedded transverse hinge elements located at spaced intervals and folding the slabs into sleeve-like parallelogram modules or tunnels. The modules are stacked and grouted together in various arrangements to form four part structural elements of a building. The hinge elements are folded annealed metal strips having cut-out slots for interfitting with the reinforcing wires, punched-out tabs for embedding in the concrete slab, and notches to produce a plane of weakness at the bending point.

United States Patent 1 1 Weese [111 3,744,196 [451 July 10,1973

[54] HINGED SLAB SYSTEM OF BUILDING [76] Inventor: Harry M. Weese, 10 W. Hubbard St.,

Chicago, 111. 60610 [22] Filed: Sept. 20, 1971 [21] Appl. No.: 181,693

52 US. CL, 52/70, 52/236, 52/745 [51] Int. Cl E041.) l/344 [58] Field of Search 52/745, 79, 236, 52/79, 77

[56] References Cited UNITED STATES PATENTS 3,494,092 2/1970 Johnson 52/69 1,361,831 12/1920 Crew 52/281 1,218,846 3/1917 Farnquist 52/70 2,035,595 3/1936 Crowe 52/432 2,645,114 7/1953 Amirikian... 52/236 2,826,157 3/1958 Vartia 52/745 3,593,482 7/1971 Johnson 52/69 3,609,935 10/1971 Thomas 52/745 FOREIGN PATENTS OR APPLICATIONS 82,772 6/1954 Denmark 52/745 4/1960 Italy 52/745 4/1966 France ..52/745 Primary Examiner-Frank L. Abbott Assistant Examinen-I-l. E. Raduazo Attorney-Johnson, Dienner, Emrich, Verbeck &

Wagner 5 Claims, 22 Drawing Figures Va 2 m g; my: 4

fl/V/Ql PAIENIED JUL 1 men same 0F 5 PAIENIEU JUL 1 mm samaurs PATENIEU JUL 1 3.744.196

SHEET u 0F 5 IIINGED SLAB SYSTEM OF BUILDING INTRODUCTION TO THE INVENTION This invention relates to an efficient and economical building system for constructing modular buildings and involves on-site extrusion or casting of structural components. These structural components are assembled together in either single or multi-story to form buildings suitable as row houses or apartment buildings.

The process and structures of this invention relate to casting and erection of a plurality of sleeve-like parallelogram modules that are connected together in various arrangements to provide a modular building construction. In the most highly developed version, on-site continuous or semi-continuous longitudinally reinforced slabs are cast by using an extra wide paving machine with embedded transverse hinges disposed at selected intervals upon a casting bed which can be the ground floor slab.'Alternatively, the slabs can be reinforced and cast conventionally.

These hinges are folded annealed metal strips having cut-out slots to interfit with the reinforcing wires and punched-out tabs embedded in the concrete slab. The hinges provide the means to fold the slabs into sleevelike parallelogram modules and include a notch bearing surface to take the vertical loads of the horizontal slabs into the vertical slabs. These notches provide a gap for cutting the continuous reinforcing wires. The modules are then erected and grouted together by pumping through a hole in the shim block.

Interior modules, such as bathrooms, kitchens, and stairs, are inserted into the structure before facade structures close the end of the parallelogram modules.

DESCRIPTION OF DRAWINGS For abetter understanding of this invention reference may be made to the accompanying drawings, in which: v I

FIG. 1 is a diagrammatic front view of a series of three-sided modular units;

FIGS. 2 3 are diagrammatic front views of additional modular units assembled together with the modular units of FIG. 1 to form a building structure;

FIGS. 4 8 are diagrammatic perspective views, respectively, of a three-sided parallelogram module, a four-sided parallelogram module, a two-sided slab, a one-sided slab, and a three-sided parallelogram module;

FIG. 9 is a diagrammatic side view of the assembly used to provide on-site reinforced slabs constructed in accordance with the principles of this invention;

FIG. 10 is a plan view of the portion-of FIG. 9 shown between the arrows III-10;

' FIG. 1 l is a four-slab unit constructed in accordance with the principles of this invention prior to being assembled into a sleeve-like parallelogram module;

FIG. '12 is a four-slabunit depicted in FIG. 11 shown in the assembled position above and between two other already set slab units;

FIG. 13 is a front perspective view of a three-story building constructed in accordance with the principles of this invention;

FIG. 14 depictsv a parallelogram module embodying the principles of this invention in the unassembled position;

FIG. 15 depicts the parallelogram module identical to FIG. 14 in its assembled position;

FIG. 16 is a perspective view of a shim used during the grouting of a plurality of parallelogram modules;

FIG. 17 is a side elevational view of one embodiment of a novel hinge element;

FIG. 18 is another embodiment of a four slab unit constructed in accordance with the principles of this invention prior to being assembled into a parallelogram module;

FIG. 19 is a partial enlarged cross-sectional view of FIG. 18;

FIG. 20 is a partial broken-away cross-sectional view of the four slab unit of FIG. 18 showing the parallelogram module mounted on two other already set modules;

FIG. 21 shows a second embodiment of a novel hinge element used in the FIGS. 18-20 embodiment; and

FIG. 22 is a face view of the hinge of FIG. 21 shaped in the form shown in FIG. 21 and with transverse reinforcing wires interleaved between its tabs.

DESCRIPTION OF PREFERRED EMBODIMENTS Referring to FIGS. 1 through 8, there are shown diagrammatic representations of module units that are as sembled together to form one-story (FIG. 1), two-story (FIG. 2) and three-story (FIG. 3) buildings.

FIG. 4 depicts three slabs 20 hinged together to provide a three-side unit A, which when set up on a base slab 22 (FIGS. 1-3) forms a sleeve-like module. In FIG. 1, adjacent units A are interconnected by a single slab D (FIG. 7) to produce a one-story structure. Outer and inner doors 24 and windows 26 can be formed in the side walls of units A. To complete the one-story structure of FIG. 1, it would of course be necessary to seal off the open ends.

To construct a two-story structure, four-sided units B (FIG. 5) comprising four hingedly-connected together slabs 28 are seated between the upper corners of adjacent spaced three-sided units A, and an end module is formedby adding a two-sided slab unit C (FIG. 6) comprising two hingedly connected slabs 30. Single slab D (FIG. 7) could be connected between the upper corners of the B units to complete the second level. The four-sided units Blikewise have inner and outer doors 32. At least one of the B units (FIG. 5) and one of the A units (FIG. 8) have formed openings 34 and 36 for a stairway entrance to the second level.

The invention is directed to a method and apparatus for making and assembling hingedly connected slabs to selectively build modular buildings as diagrammatically depicted in FIGS. 1. through 8.

In FIGS. 9 and 10, there is diagrammatically shown an on-site system for making the sleeve-like parallelogram modules in accordance with the principles of this invention. A plurality of closely spaced longitudinally extending prestressed reinforcing wires 40 (FIG. 10) are connected between an end anchor 42 and a tensioning reel 44. An extra wide paving machine 46 guided on rails 48 moves away from anchor 42 to pour a first layer and then returns to its starting position to lay a second layer. A parting agent is used to separate the two layers and openings 43 are box outs for stairwells, windows, doors, etc. Novel hinge elements 50 (FIG. 14) are embedded at selected intervals transverse to the reinforcing wires 40 to permit the casted slabs to be folded into open-ended sleeve-like parllelogram modules 52.

One embodiment of the novel hinge element 50 of this invention is depicted in FIG. 17, and comprises an elongated metal strip 52 folded lengthwise into two equal portions to define hinge plates 51 and 53 (FIG. 14). Notches 54 are provided along its longitudinal centerline to induce bending, and along its longitudinal edge are cut-outs 56 spaced apart an amount equal to the distance between reinforcing wires 40 for straddling about these wires, which leave access for cutting the reinforcing wires between the slabs. Tabs 58 are punched out along both sides of the folded portions of the strip 52 and are bent into a hook shape for anchoring in adjacent slabs to provide a hinging effect between slabs.

.FIG. 14 depicts a parallelogram module 52 before it is set up. The two lower slabs 60 and 62 are extruded on the first pass of the paving machine and the two upper slabs 64 and 66 are extruded on the second pass. It is of course necessary to bend half of the two exterior hinge elements upwardly before the second pass. Spacers (not shown) hold the opposite ends of the slabs in place during curing. When cured, the upper slabs 64 and 66 are swung in the direction of the arrows from the solid line position of FIG. 11 (dotted lines in FIG. 11 show intermediate position) to the position of FIG. 12.

FIG. 12 shows the stacking and assembly of a para]- lelogram module 12 above and between two already set modular units. A jig or brace 70 is used to keep the module square while the square-shaped space 71 formed by the adjoining corners is filled with grout through a hole 73 in the shims 72 (FIG. 16).

The hinge elements shown in FIG. 14 are adapted to swing counterclockwise. The hinge element 68 in the upper layer is identical to hinge element 50 in the lower layer except pentagon-shaped cut-outs 69 are provided to accommodate the rods 40 instead of slots 56 used in hinge 50. These cut-outs are sufficiently large to permit access for cutting reinforcing wires 40.

FIG. shows a parallelogram module 52 in its setupposition with its lower right corner grouted to the upper left corner of another parallelogram module. The shim 72 (FIG. 16) is disposed in the square-shaped gap 74 before filling it with grout. Thus, the parallelogram modules bear on shims and the pumped grout without any overlap of the precast segments, i.e., hearing forces are carried from upper walls to lower walls on the grout infill, which also fill the notches in supporting the floors.

FIG. 13 shows a front perspective view of a threestory building 80 constructed by assembling a pluraity of parallelogram modules made and grouted together in accordance with the foregoing description. An end filler 82 fills the recess formed between theoutside corner edges of adjacent slabs. The open ends are closed with a facade structure 84 which is manufactured offsite. These structures are self-supporting and contain mechanical equipment such as furnaces, boilers, air conditioning units, electric and gas meters, fuse boxes, fireplaces, closets, balconies, etc.

Site finishing is limited to an optional skim coating of concrete surfaces, dry walling the stud assemblies, under-layment, flooring, exposed wiring, plumbing connections to modules, painting, carpeting, and the hanging of pre-fit doors.

There is shown in FIGS. 18-22, another version of a parallelogram module which embodies the principles of this invention and which is formed in the same manner as described hereinbefore. The hinge element is made of an elongated metal strip which is folded along its centerline into two equal portions to define a pair of binge plates 92 and 94. Tabs 96 having hook ends 98 are cut transversely to its centerline, and are bent so that transverse reinforcing wires 100 interleave between alternate tabs that are separated by an acute angle to provide an alternate staggered arrangement.

Triangular shaped recesses 102 are formed at the ends of the longest pair of slabs 104 and 106. The purpose of these recesses is to provide a means for gaining access to the longitudinally extending reinforcing wires 100, which pass through the recess 102. As shown in FIG. 20, the ends of the reinforcing wires at the exterior hinges are of such a length to intertwine and thereby provide continuity to one-half the joints.

As many changes could be made in the above described module building construction, and many widely different embodiments of this invention could be made without departure from the scope of the claims, 'it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

Having now particularly described and ascertained the nature of the invention, and in what manner the same is to be performed, what is claimed is:

l. A modular unit for use in a modular building comprising four casted slabs hingedly-connected together in an open-ended sleeve-like parallelogram configuration, a plurality of reinforcing w-ires extending in a generally parallel plane through the entire length of each of said slabs, and four integral hinge elements connecting said slabs together, each of said hinge elements comprising an elongated sheet of bendable high strength material folded lengthwise to present two hinge plates, a plurality of tabs projecting outwardly in each of said hinge plates at a transverse angle to said parallel plane with at least a portion of said tabs embed-' ded in the ends of said slabs, and a plurality of slots formed through said hinge plates to provide passageways for said reinforcing wires, the portion of said hinge plate about each of said slots projecting inwardly of its associated slab a sufficient distance to provide access for severing said reinforcing wires when said modular unit is in its flattened pre-assembled position.

2. A modular unit as defined in claim 1, wherein the ends of said reinforcing wires extend outwardly of the opposite ends of each slab a sufficient distance to provide structural continuity with adjacent slabs when stacked together.

3. A modular unit as defined in claim 1, wherein said plurality of slots are formed along the lateral edges of said hinge plates and said lateral edge is bent inwardly of its associated slab to define said inwardly projecting portion.

4. A modular unit as defined in claim 1, wherein said tabs extend substantially the entire width of said hinge plates and adjacent tabs are separated by an acute angle to provide an alternate staggered arrangement.

5. A modular unit as defined in claim 3, further comprising transverse reinforcing wires interleaved between said alternate staggered tabs for each of said hinge plates.

i I I III 

1. A modular unit for use in a modular building comprising four casted slabs hingedly-connected together in an open-ended sleevelike parallelogram configuration, a plurality of reinforcing wires extending in a generally parallel plane through the entire length of each of said slabs, and four integral hinge elements connecting said slabs together, each of said hinge elements comprising an elongated sheet of bendable high strength material folded lengthwise to present two hinge plates, a plurality of tabs projecting outwardly in each of said hinge plates at a transverse angle to said parallel plane with at least a portion of said tabs embedded in the ends of said slabs, and a plurality of slots formed through said hinge plates to provide passageways for said reinforcing wires, the portion of said hinge plate about each of said slots projecting inwardly of its associated slab a sufficient distance to provide access for severing said reinforcing wires when said modular unit is in its flattened preassembled position.
 2. A modular unit as defined in claim 1, wherein the ends of said reinforcing wires extend outwardly of the opposite ends of each slab a sufficient distance to provide structural continuity with adjacent slabs when stacked together.
 3. A modular unit as defined in claim 1, wherein said plurality of slots are formed along the lateral edges of said hinge plates and said lateral edge is bent inwardly of its associated slab to define said inwardly projecting portion.
 4. A modular unit as defined in claim 1, wherein said tabs extend substantially the entire width of said hinge plates and adjacent tabs are separated by an acute angle to provide an alternate staggered arrangement.
 5. A modular unit as defined in claim 3, further comprising transverse reinforcing wires interleaved between said alternate staggered tabs for each of said hinge plates. 